L’hydrodémolition augmente la productivité d’un projet de pont aux Philippines

 

Quel que soit le projet – qu’il s’agisse d’une simple structure ou d’un pont massif de plusieurs millions de dollars – une construction efficace nécessite une planification minutieuse. Cependant, même avec une logistique sans faille, les projets peuvent rencontrer des difficultés qui mettent en péril les délais.

 

Aux Philippines, la construction d’un gigantesque pont reliant Cebu City à Cordova, à l’extrémité sud de l’île de Mactan, est actuellement en cours. L’autoroute Cebu-Cordova Link, d’une longueur de 8,5 kilomètres (5,3 miles), dont l’achèvement est prévu en 2021, enjambera le canal de Mactan avec un espace de navigation de 51 mètres (167 pieds) pour les navires de transport. Elle promet de réduire la congestion entre Cebu et Mactan et de stimuler les activités économiques dans toute la région en offrant un accès supplémentaire à l’île et à l’aéroport international de Mactan-Cebu pour un nombre de véhicules estimé à 50 000 par jour.

Comme prévu, la construction – l’un des plus grands projets d’infrastructure du pays – repose sur un plan soigneusement chorégraphié d’opérations simultanées afin de respecter des délais stricts. Une logistique experte permet aux équipes d’éviter de nombreux obstacles ; cependant, des défis imprévus peuvent toujours survenir. Lorsqu’un mauvais lot de béton a menacé de faire dérailler la progression de l’un des premiers piliers du pont, les responsables du projet ont eu besoin d’une solution créative qui permettrait de démonter rapidement le béton de mauvaise qualité sans endommager les barres d’armature et sans retarder le projet. L’hydrodémolition était le seul procédé offrant la précision et la productivité nécessaires pour maintenir le projet sur les chenilles.

Cebu Link Joint Venture (CLJV) a contacté la société Asia Waterjet Equipment, basée à Singapour, les premiers experts en hydrodémolition de la région. L’accès et les conditions du site représentaient un véritable défi, mais avec des décennies d’expérience dans certaines des applications les plus dangereuses, Asia Waterjet Equipment était plus qu’à la hauteur de la tâche. Alors que l’heure tournait et que la mousson battait son plein, l’équipe est arrivée sur le site avec un robot d’hydrodémolition Aqua Cutter 710V et une pompe jet d’eau Jetstream HP.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Lorsqu’un mauvais lot de béton a menacé de faire dérailler l’avancement d’un important projet de pont aux Philippines, Asia Waterjet Equipment s’est tourné vers Aquajet pour trouver une solution créative permettant de démonter rapidement le béton de mauvaise qualité sans endommager les barres d’armature et sans retarder le projet.

 

 

Passion pour la résolution de problèmes

Au début des années 1990, les fondateurs d’Asia Waterjet Equipment faisaient partie des équipes courageuses chargées de contenir les puits de pétrole au Koweït qui avaient été détruits pendant la guerre du Golfe persique. Leur expérience a permis d’éviter une énorme crise environnementale. Ils sont restés au Moyen-Orient et ont finalement fondé Asia Waterjet Equipment en 2006, apportant le jet d’eau haute pression et l’hydrodémolition robotisée au Moyen-Orient et à l’Asie du Sud-Est.

Aujourd’hui, avec des bureaux à Dubaï, Abou Dhabi, en Arabie saoudite, à Bahreïn et à Singapour et une forte présence et des partenariats dans tous ces territoires, l’entreprise est connue pour sa créativité dans la résolution des problèmes, offrant des solutions innovantes de découpe et de nettoyage pour les zones dangereuses ou les produits difficiles à pomper dans les secteurs de la pétrochimie, des eaux usées, de l’exploitation minière, de la construction et dans d’autres industries. Elle propose également une gamme de solutions robotiques pour aider les clients à protéger leurs employés et à dépasser leurs attentes.

“Notre objectif a toujours été de fournir des outils de pointe pour rendre les applications difficiles plus sûres et plus efficaces”, a déclaré Chris Parkhill, directeur des ventes d’équipements à jet d’eau pour l’Asie du Sud-Est. “Dès le début, nous avons été impliqués dans certaines des opérations les plus dangereuses qui soient. Nous comprenons les exigences et les dangers, c’est pourquoi nous nous associons à des fabricants d’équipements de pointe pour proposer des solutions robustes qui maximisent la sécurité et la productivité.”

En associant les bons outils à des membres d’équipe expérimentés qui apportent à chaque projet une connaissance approfondie de l’industrie et des marchés locaux, Asia Waterjet Equipment a acquis la réputation de produire des résultats de grande qualité. Sur les marchés émergents, tels que les Philippines, où les exigences des projets de plusieurs millions de dollars sont devenues un terrain d’essai pour des technologies plus récentes et plus efficaces, cette expertise place l’entreprise à l’avant-garde.

“De l’Afrique du Nord à l’Asie du Sud-Est, nous couvrons beaucoup de terrain”, a déclaré M. Parkhill. “Mais être capable de rencontrer l’entrepreneur là où il se trouve est la clé d’une solution réussie. En travaillant avec CLJV, nous avons dû relever un certain nombre de défis pour maintenir le projet sur les chenilles. L’hydrodémolition était la meilleure solution et Aquajet était le meilleur outil pour ce travail.”

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Pour protéger les barres d’armature et le bon béton existant, Asia Waterjet Equipment savait que l’hydrodémolition était la seule solution. Cette méthode non intrusive utilise des jets d’eau haute pression d’une puissance de 40 000 psi manipulés par un robot automatisé pour démonter les couches de béton détérioré et endommagé.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Les équipes équipées de brise-roche manuels ou d’excavateurs pouvaient démonter le béton de mauvaise qualité, mais seulement en détruisant les barres d’armature. Asia Waterjet Equipment savait que l’hydrodémolition était le seul procédé offrant la précision et la productivité nécessaires pour maintenir le projet sur les rails.

 

 

L’eau trouble

L’accès était le principal problème. CLJV menait simultanément des travaux de construction sur plusieurs piliers de pont. Afin de minimiser les perturbations pour la communauté locale, l’aire de transit principale du projet, ainsi que le premier pilier, n’étaient accessibles que depuis la côte. Le béton devait donc être mélangé à 2,5 kilomètres de la côte, puis transporté par barge jusqu’au chantier. De là, la barge était échouée et les camions débarquaient directement sur la plage. Le pilon se trouvait à 30 mètres (98 pieds) à l’intérieur des terres.

Dans l’ensemble, le retard de transport n’a pas eu d’impact négatif sur le béton, et le pilon de 16 mètres sur 14 (52,5 sur 45,9 pieds) a rapidement atteint 4 mètres de haut. Cependant, une complication au niveau d’une seule livraison a menacé de retarder l’ensemble du projet et de dépasser le budget.

“Lorsque vous travaillez avec du béton, il arrive que les choses ne se passent pas comme prévu”, explique M. Parkhill. “Il s’agit d’une équation délicate, après tout, et même une légère erreur de calcul peut ruiner le mélange. Malheureusement, lorsque cela se produit, il n’y a pas de solution facile”.

Les équipes ont su immédiatement qu’il y avait un problème. Le béton était déjà en train de prendre pendant qu’ils pompaient. La vibration et les autres méthodes de correction ont échoué, et la coulée s’est finalement soldée par un échec. Pire encore, il manquait 350 millimètres (13,8 pouces) de béton, ce qui laissait un filet de barres d’armature exposées.

Pour CLJV et Asia Waterjet Equipment, les défis s’accumulaient, rendant la réparation très difficile. Le pilon était presque terminé. Bien que CLJV ait prévu du temps et de l’argent pour les petites complications, elle ne pouvait pas se permettre de démolir l’ensemble du pilier et de recommencer.

Les équipes équipées de brise-roche portatifs ou de pelles hydrauliques ont pu procéder au démontage du béton de mauvaise qualité, mais seulement en détruisant les barres d’armature. Elles devaient couper les barres d’armature exposées au sommet du pilier pour accéder au béton situé un pied plus bas. D’autres barres d’armature seraient endommagées au fur et à mesure du démontage du béton de mauvaise qualité, et les microfractures provoquées par les vibrations des marteaux-piqueurs ou des excavatrices affaibliraient le béton restant, mettant en péril l’intégrité du pilier.

“Il n’y avait pas d’autre choix : les barres d’armature et le bon béton existant devaient être protégés”, explique M. Parkhill. “Si CLJV avait utilisé des méthodes de démolition traditionnelles, elle aurait dû ouvrir, écarter là où c’était possible ou couper les barres d’armature et extraire manuellement le mauvais béton à l’aide d’un marteau-piqueur. Il n’y a aucune garantie qu’un homme utilisant un marteau-piqueur puisse évaluer ce qui est bon et ce qui est mauvais, de sorte qu’ils finiraient par en enlever davantage. Il faudrait ensuite plier les barres d’armature pour les remettre en place sans les casser, ou souder ou couper de nouveaux filets et les assembler à l’aide de raccords filetés. Cela aurait ajouté des semaines au projet et un coût important au budget. Ils ne pouvaient tout simplement pas se le permettre”.

Asia Waterjet Equipment savait que l’hydrodémolition était la seule solution. Cette méthode non intrusive utilise des jets d’eau haute pression d’une puissance de 40 000 psi manipulés par un robot automatisé pour démonter les couches de béton détérioré et endommagé. L’eau à haute pression dépasse la résistance du béton pour élargir les pores et les microfissures existantes, le désagrégeant de manière contrôlée. Contrairement à d’autres méthodes mécaniques, l’hydrodémolition est sans impact, ce qui élimine les vibrations à l’origine des microfractures.

En outre, la méthode est conforme aux normes européennes EN 1504 et offre une surface d’adhérence supérieure pour le nouveau béton. Le jet d’eau haute pression de l’Aqua Cutter 710V laisse un profil rugueux et irrégulier après avoir démonté la couche initiale de béton, ce qui se traduit par une meilleure force d’adhérence. Le robot nettoie et détartre également les barres d’armature exposées et élimine les contaminants non visibles tels que la saleté, la boue, la boue de fondation, les sels, les chlorures et les sulfates.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Avec sa capacité à réaliser des tâches de démontage du béton jusqu’à 25 fois plus rapidement qu’une lance manuelle, l’Aqua Cutter d’Aquajet a fourni la solution nécessaire pour maintenir le projet d’Asia Waterjet Equipment dans les délais.

 

 

Construire des ponts

La productivité était également un problème. Les travaux de construction se poursuivant simultanément sur plusieurs autres piliers dans la région, les équipes devaient procéder au démontage du béton de mauvaise qualité et effectuer les réparations rapidement, avec un minimum de main-d’œuvre.

Capable de réaliser des travaux de démontage du béton jusqu’à 25 fois plus rapidement qu’une lance manuelle, l’Aqua Cutter a fourni la solution nécessaire pour respecter le calendrier du projet. Asia Waterjet Equipment a fait appel à Kjell Isaksson, responsable des applications spéciales d’Aquajet, pour soutenir l’opération.

“Il y avait beaucoup de variables et pas de place pour l’erreur”, a déclaré M. Parkhill. “Pour minimiser les risques de retard, nous avons décidé qu’il serait préférable d’avoir un spécialiste Aquajet sur place.”

Tout comme les camions de ciment, l’Aqua Cutter et tout l’équipement de soutien, y compris un bloc d’alimentation à jet d’eau haute pression équipé d’une pompe Jetstream de la série 4200, devaient accéder au site depuis le Chanel de Mactan. La proximité de l’eau et les pluies fréquentes et abondantes de la mousson ont rendu les conditions du terrain difficiles. Cependant, comme l’Aqua Cutter est autopropulsé avec des chenilles, le terrain inégal et boueux n’a posé aucun problème à Asia Waterjet Equipment. Cela a permis de minimiser les préparations nécessaires sur le site et d’accélérer les réparations.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

Le terrain irrégulier et boueux du chantier n’a posé aucun problème à l’Aqua Cutter automoteur. Cela a permis de minimiser les préparations nécessaires sur le site et d’accélérer les réparations.

Traverser le pont de la réussite

Cette mobilité était également nécessaire pour s’attaquer à la démolition elle-même. Une fois soulevé par une grue à 4 mètres (13 pieds) du sommet du pieu, l’Aqua Cutter a pu facilement manœuvrer sur les barres d’armature. La pompe haute pression a été installée à 7 mètres de distance et reliée au robot Hydrodémolition par un tuyau haute pression.

Pour réduire les coûts et augmenter la production, Asia Waterjet Equipment a choisi d’utiliser de l’eau de mer pour la majeure partie de la démolition plutôt que d’apporter de l’eau douce. L’entreprise a continuellement rempli deux réservoirs de nuit de 20 mètres cubes (5 283 gallons) directement à partir du Mactan Chanel. L’eau douce n’a été utilisée que pendant les deux derniers jours du projet afin d’éliminer le sel et les autres impuretés susceptibles de nuire à l’adhérence.

À l’aide du robot Hydrodémolition, fonctionnant à 1 000 bars (15 000 psi), et de deux employés, Asia Waterjet Equipment a démonté 10 mètres cubes (13 yards cubes) de béton de mauvaise qualité à une profondeur de 150-250 millimètres (6-10 pouces) en quelques jours.

” Grâce à l’Aqua Cutter, nous avons augmenté la productivité à un point tel que la construction a repris dans les délais “, a déclaré Parkhill. “Sans Hydrodémolition, il n’y a aucune chance que CLJV ait pu faire cela”.

 

No matter the project — from a simple structure to a massive, multi-million-dollar bridge system — efficient construction requires thorough planning. But, even with flawless logistics, projects can run into challenges that put deadlines in jeopardy. Construction is currently underway in the Philippines on a massive bridge system connecting Cebu City with Cordova on the southern end of Mactan Island. The 8.5-kilometer (5.3-mile) Cebu-Cordova Link Expressway, slated for completion in 2021, will span the Mactan Channel with 51-meter (167-feet) navigational clearance for shipping vessels. It promises to ease congestion between Cebu and Mactan and boost economic activities throughout the region by providing additional access to the island and the Mactan-Cebu International Airport for an estimated 50,000 vehicles a day. As expected, the construction — one of the largest infrastructure projects in the country — relies on a carefully choreographed plan of simultaneous operations to meet strict deadlines. Expert logistics allow crews to avoid many hurdles; however, unforeseen challenges can still arise. When a bad batch of concrete threatened to derail progress on one of the bridge’s first pilons, project managers needed a creative solution that could quickly remove the poor-quality concrete without damaging the rebar or putting the project behind schedule. Hydrodemolition was the only process with the precision and productivity to keep the project on track. Cebu Link Joint Venture (CLJV) contacted Singapore-based Asia Waterjet Equipment, the region’s premier Hydrodemolition experts. Access and site conditions presented quite a challenge, but with decades of experience in some of the most hazardous applications, Asia Waterjet Equipment was more than up to the task. With the clock ticking and monsoon season in full swing, the team arrived onsite with an Aquajet Aqua Cutter 710V Hydrodemolition robot and Jetstream HP Waterjetting Pump. Passion for Problem Solving In the early 1990s, Asia Waterjet Equipment’s founders were part of the brave crews tasked with containing oil wells in Kuwait that were destroyed during the Persian Gulf War. Their experience helped avert a huge environmental crisis. They remained in the Middle East, eventually founding Asia Waterjet Equipment in 2006, bringing high-pressure water jetting and robotic Hydrodemolition to the Middle East and South East Asia. Now, with offices in Dubai, Abu Dhabi, Saudi Arabia, Bahrain and Singapore and a strong presence and partnerships throughout these territories, the company is known for creative problem solving — delivering innovative cutting and cleaning solutions for hazardous areas or difficult to pump products in petrochemical, wastewater, mining, construction and other industries. They also offer a range of robotic solutions to help customers protect employees and perform beyond expectations. “Our focus has always been providing the cutting-edge tools to make challenging applications safer and more efficient,” said Chris Parkhill, Asia Waterjet Equipment Sales Director for Southeast Asia. “From the very beginning, we’ve been involved in some of the most hazardous operations out there. We understand the demands and dangers, which is why we partner with industry-leading equipment manufacturers for robust solutions that maximize safety and productivity.” Pairing the right tools with experienced team members who bring a wealth of industry knowledge and a deep understanding of local markets to each project has earned Asia Waterjet Equipment a reputation for high-quality results. In emerging markets, such as the Philippines, where the demands of multi-million-dollar projects have become a proving ground for newer, more efficient technologies, this expertise puts the company at the forefront. “From North Africa to South East Asia, we cover a lot of ground,” Parkhill said. “But being able to meet the contractor where they are is key to a successful solution. Working with CLJV, there were a number of challenges we had to overcome to keep the project on track. Hydrodemolition was the best solution and Aquajet was the best tool for the job.” Troubled Water Access was the primary problem. CLJV was conducting construction on several bridge pilons simultaneously. To minimize disruptions to the local community, the project’s primary staging area, as well as the initial pilon, were only accessible from the coast. This meant the concrete had to be mixed 2.5 kilometers (1.6 miles) down the coast then transported by barge to the jobsite. From there, the barge was grounded, and the trucks disembarked directly onto the beach. The pilon was 30 meters (98 feet) inland. Overall, the transportation delay had no negative impacts on the concrete, and the 16-by-14-meter (52.5-by-45.9-foot) pilon quickly grew to 4 meters (13 feet) tall. However, a complication with a single delivery threatened to throw the entire project behind schedule and over budget. “When you are working with concrete, sometimes things don’t go to plan,” Parkhill said. “It’s a delicate equation, after all, and even a slight miscalculation can ruin the mixture. Unfortunately, when that happens, there isn’t an easy fix.” Crews knew there was a problem immediately. The concrete was already setting as they pumped. Vibrating and other correctional methods failed, and the pour was ultimately unsuccessful. Even worse, the concrete fell 350 millimeters (13.8 inches) short, leaving a mesh of exposed rebar. For CLJV and Asia Waterjet Equipment, the challenges were adding up, making for a very difficult repair. The pilon was nearly complete. While CLJV had budgeted time and money for small complications, it could not afford to demolish the whole pilon and start over. Crews with handheld breakers or excavators could remove the poor-quality concrete, but only by destroying the rebar. They would have to cut the exposed rebar at the top of the pilon to access the concrete a foot below. More rebar would be damaged as the poor-quality concrete was removed, and microfractures from the vibration of jackhammers or excavators would weaken the remaining concrete, jeopardizing the pilon’s integrity. “There was no option; the rebar and existing good concrete had to be protected,” Parkhill said. “If CLJV went with traditional demolition methods, they’d have to open, pry apart where possible or cut the rebar and manually jack hammer out the bad concrete. There’s no guarantee a man using a jack hammer could gauge what’s good and what’s bad, so they’d end up removing extra. Then they’d have to bend the rebar back into place without breaking it, or weld or cut new threads and join with it threaded couplers. It would add weeks to the project and a significant cost to the budget. They simply couldn’t afford it.” Asia Waterjet Equipment knew Hydrodemolition was the only solution. The non-intrusive method uses high-pressure water jets as powerful as 40,000 psi manipulated by an automated robot to remove layers of deteriorated and damaged concrete. The high-pressure water exceeds the strength of the concrete to widen existing pores and microcracks, breaking it apart in a controlled manner. Unlike other mechanical methods, Hydrodemolition is impact free, eliminating the vibrations that cause microfractures. Additionally, the method meets European Standards EN 1504 and provides a superior bonding surface for new concrete. The Aqua Cutter 710V’s high-pressure water jet leaves a rough, irregular profile after removing the initial layer of concrete that results in a better bonding strength. The robot also cleans and descales the exposed rebar and removes non-visible contaminants such as dirt, mud, foundation mud, salts, chlorides and sulfates. Building Bridges Productivity was also a concern. With simultaneous construction continuing on several other pilons in the area, crews needed to remove the poor-quality concrete and complete repairs quickly — with minimal labor. With the ability to complete concrete removal tasks up to 25 times faster than a hand lance, the Aqua Cutter provided the necessary solution to keep the project on schedule. Asia Waterjet Equipment brought in Aquajet Special Application Manager Kjell Isaksson to support the operation. “There were a lot of variables and no room for error,” Parkhill said. “To minimize the risk of delays, we decided it would be best to have an Aquajet specialist on site.” Like the cement trucks, the Aqua Cutter and all support equipment, including a high-pressure waterjet power pack with a 4200 series Jetstream pump, had to access the site from the Mactan Chanel. Proximity to the water and the frequent, heavy rains of monsoon season made ground conditions difficult. However, since the Aqua Cutter is self-propelled with tracks, the uneven, muddy terrain presented no problems for Asia Waterjet Equipment. This minimized necessary site preparations and helped accelerate repairs. Crossing the Bridge to Success This mobility was also necessary for tackling the demolition itself. Once lifted the 4 meters (13 feet) onto the pile cap by a crane, the Aqua Cutter was able to easily maneuver over the rebar. The high-pressure pump was setup 7 meters (23 feet) away and connected to the Hydrodemolition robot by a high-pressure hose. To help reduce cost and increase production, Asia Waterjet Equipment opted to use seawater for the majority of the demolition rather than bring in fresh water. The company continually filled two 20-cubic meter (5,283 gallon) night tanks directly from the Mactan Chanel. Fresh water was only used during the last two days of the project to remove salt and other impurities that could impact bonding. Using the Hydrodemolition robot, operating at 1,000 bar (15,000 psi), and two employees, Asia Waterjet Equipment removed 10 cubic meters (13 cubic yards) of poor-quality concrete at a depth of 150-250 millimeters (6-10 inches) in days. “With the Aquajet Aqua Cutter, we increased productivity to a point where construction was back on schedule,” Parkhill said. “Without Hydrodemolition, there’s no way CLJV would have been able to do that.” The Future of Hydrodemolition While construction on the bridge system continues, Asia Waterjet Equipment is already on to the next challenge. “Construction in Southeast Asia is changing,” Parkhill said. “Robotic processes like Hydrodemolition are proving you can have productivity and safety. With innovative partners like Aquajet, Asia Waterjet Equipment is playing a leading role in facilitating that change.”

À l’aide du robot Hydrodémolition, fonctionnant à 1 000 bars (15 000 psi), et de deux employés, Asia Waterjet Equipment a démonté 10 mètres cubes (13 yards cubes) de béton de mauvaise qualité à une profondeur de 150-250 millimètres (6-10 pouces).

 

 

L’avenir de l’hydrodémolition

Alors que la construction du pont se poursuit, Asia Waterjet Equipment s’attaque déjà au prochain défi.

“La construction en Asie du Sud-Est est en train de changer”, a déclaré M. Parkhill. “Les processus robotisés comme l’hydrodémolition prouvent que vous pouvez avoir la productivité et la sécurité. Avec des partenaires innovants comme Aquajet, Asia Waterjet Equipment joue un rôle de premier plan pour faciliter ce changement.”

 

 

 

En bref

Lieu :
Pont massif reliant Cebu City à Cordova, à l’extrémité sud de l’île de Mactan, aux Philippines.

Projet de pont :
La Cebu-Cordova Link Expressway, d’une longueur de 8,5 kilomètres (5,3 miles), devrait être achevée en 2021. Elle enjambera le canal de Mactan avec une hauteur libre de 51 mètres (167 pieds) pour la navigation des navires.

Projet d’hydrodémolition :
Démontage sélectif du béton de mauvaise qualité sans endommager les barres d’armature ni retarder le projet.

Matériaux démolis :
10 mètres cubes de béton de mauvaise qualité à une profondeur de 150-250 millimètres (6-10 pouces).

Équipement : Aqua Cutter 710V.

 

 

Plus d’informations

Aqua Cutter 710V

Hydrodémolition

Réseau mondial de distributeurs Aquajet

 

 

pdf imprimable

Aquajet On location – La solution robotique innovante d’Aquajet assure la productivité d’un projet de pont aux Philippines.